U.S. patent number 4,529,348 [Application Number 06/482,691] was granted by the patent office on 1985-07-16 for spout aimer.
This patent grant is currently assigned to Deere & Company. Invention is credited to Gary L. Gold, Stanley J. Johnson.
United States Patent |
4,529,348 |
Johnson , et al. |
July 16, 1985 |
**Please see images for:
( Certificate of Correction ) ** |
Spout aimer
Abstract
A spout control system permits automatic and manual control of a
forage harvester spout which directs crop to a receiving wagon.
Under certain conditions, the control system automatically sweeps
the spout in a stepwise manner through a series of positions to
achieve uniform wagon filling. This and other functions are
achieved with the use of a suitably programmed microprocessor.
Inventors: |
Johnson; Stanley J. (Cedar
Falls, IA), Gold; Gary L. (Waterloo, IA) |
Assignee: |
Deere & Company (Moline,
IL)
|
Family
ID: |
23917047 |
Appl.
No.: |
06/482,691 |
Filed: |
April 6, 1983 |
Current U.S.
Class: |
414/335; 406/28;
406/165 |
Current CPC
Class: |
A01D
43/07 (20130101) |
Current International
Class: |
A01D
43/00 (20060101); A01D 43/07 (20060101); B65G
067/22 () |
Field of
Search: |
;414/335,133,293,294,301,302,323,345 ;406/28,165,30 ;239/659,688
;198/631 ;193/22,23 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
E C. Lundahl, Invention Disclosure, Jan. 1, 1981 and May 15, 1981,
pp. 32, 122, 224, 229 and unnumbered..
|
Primary Examiner: Spar; Robert J.
Assistant Examiner: Millman; Stuart J.
Claims
We claim:
1. In a forage harvester having a movable crop discharge spout for
directing crop to a crop-receiving wagon and a spout aiming control
system, the improvement wherein the control system comprises:
a sweep mode which is operational to automatically move the spout
through a plurality of sweep mode positions to achieve even filling
of the wagon;
a non-sweep mode which is operational to automatically maintain a
predetermined spout-wagon angular relationship to prevent crop
spillage and wherein the spout is moved in response to changes in
an angular relationship between the forage harvester and the wagon;
and
mode selecting means for automatically making one or the other of
said modes operational, depending upon sensed conditions.
2. The invention of claim 1, wherein the control system
comprises:
a sweep mode counter having a plurality of states corresponding to
the plurality of sweep mode positions;
means for sequentially selecting among the plurality of spout sweep
mode positions, depending upon the status of the sweep mode
counter;
means for sequentially moving the spout to the selected spout sweep
mode positions; and
means for changing the state of the sweep mode counter after the
spout is moved to each selected sweep mode position.
3. The invention of claim 2, further comprising:
alignment means responsive to a predetermined spout-wagon
relationship for automatically aligning the spout with respect to a
tongue of the crop-receiving wagon; and
means changing the state of the sweep mode counter after operation
of the alignment means.
4. The invention of claim 1, further comprising:
means for preventing operation of the sweep mode whenever the spout
is positioned outside of a predetermined range of positions.
5. The invention of claim 4, wherein the predetermined range
comprises a central portion of a wagon crop-receiving range of
spout positions.
6. The invention of claim 1, further comprising:
delay means for preventing operation of the sweep mode until a
predetermined time after termination of operation of the non-sweep
mode.
7. The invention of claim 1, further comprising:
manually operable means for generating spout movement command
signals, the control system including means for moving the spout in
response to the command signals generated by the manually operable
means;
inhibit means for preventing operation of the sweep mode when the
spout is manually moved outside of a predetermined range of
positions; and
inhibit means for preventing operation of the sweep mode unless a
predetermined delay time expires following a movement of the spout
in response to the command signals generated by the manually
operable means.
8. The invention of claim 1, further comprising:
manually operable means for generating spout movement command
signals, the control system including means for moving the spout in
response to the command signals generated by the manually operable
means; and
inhibit means for preventing operation of the sweep mode when the
spout is moved outside of a predetermined range of positions in
response to the command signals generated by the manually operable
means.
9. The invention of claim 1, further comprising:
manually operable means for generating spout movement command
signals, the control system including means for moving the spout in
response to the command signals generated by the manually operable
means; and
inhibit means for preventing operation of the sweep mode unless a
predetermined delay time expires following a movement of the spout
to a position within a predetermined range of positions in response
to the command signals generated by the manually operable
means.
10. The invention of claim 1, further comprising:
means for preventing automatic movement of the spout among the
sweep mode positions when the forage harvester and wagon are
executing a turn.
11. The invention of claim 1, further comprising:
means for preventing automatic movement of the spout among the
sweep mode positions following execution of a turn by the forage
harvester and wagon unless the wagon is substantially aligned with
the fore-and-aft axis of the forage harvester for at least a
predetermined delay time after completion of the turn.
12. The invention of claim 1, wherein the sweep mode positions are
comprised of a first position substantially centered with respect
to the wagon, and second, third, fourth and fifth positions,
wherein the second and fifth positions are on opposite sides of the
first position, the third position is between the first and fifth
positions and the fourth position is between the first and second
positions.
13. The invention of claim 12, wherein the sweep mode sequentially
moves the spout from the first to the second, to the third, to the
fourth and then to the fifth position.
14. In an agricultural machine having a movable crop discharge
spout for directing crop to a crop-receiving wagon, a control unit
for automatically generating spout movement command signals as a
function of sensed parameters, operator-actuated means for manually
generating spout movement command signals and means for moving the
spout in response to the manually and automatically generated
command signals, the improvement wherein the control unit
comprises:
means for sensing manual movement of the spout to positions outside
of a wagon crop-receiving window and means for automatically
returning the spout to an edge of the crop-receiving window after
termination of a manual movement of the spout which leaves the
spout aimed outside of the crop-receiving window.
15. The invention of claim 14 wherein the moving means comprises an
electro-hydraulic valve energizable by the manually and
automatically generated command signals; and
the manual movement sensing means comprises valve sensing means for
sensing the energization of the valve and logic means for
determining that a command signal has been manually generated when
the valve sensing means senses energization of the valve when no
corresponding automatically generated command signal is
generated.
16. In an agricultural machine having a movable crop discharge
spout for directing crop to a crop-receiving wagon, a control unit
for automatically generating spout movement command signals as a
function of sensed parameters, operator-actuated means for manually
generating spout movement command signals, means for moving the
spout in response to the manually and automatically generated
command signals including an electro-hydraulic valve means
energizable by the manually and automatically generated command
signals, the improvement wherein the control unit comprises:
sensing means for sensing the energization of the valve means;
logic means for determining that a command signal has been manually
generated when the sensing means senses energization of a valve
means when no corresponding automatically generated command signal
has been generated, and
means for at least temporarily suppressing further automatic
generation of command signals in response to manual generation of a
command signal.
17. The invention of claim 16 wherein the control unit further
comprises:
alignment means for automatically aiming the spout at a central
portion of a wagon crop-receiving window and means responsive to a
manually generated command signal for disabling the alignment means
to permit the spout to be manually aimed outside of said central
window portion.
18. The invention of claim 17, wherein the control unit further
comprises:
means for automatically returning the spout to an edge of the
crop-receiving window after termination of a manual movement of the
spout which leaves the spout aimed outside of the crop-receiving
window.
19. In an agricultural machine having a movable crop discharge
spout for directing crop to a crop-receiving wagon and a control
unit which automatically maintains the spout within a narrow
position range when the machine is being steered through a turn,
which permits the spout to move within a wide position range when
the machine is not turning and which includes delay means for
maintaining the spout within the narrow range for a certain time
period after a turn is completed, the improvement wherein the
control unit comprises:
means for distinguishing between manually and automatically
produced movement of the spout and for overriding the delay means
to permit manual positioning of the spout outside of the narrow
range immediately upon termination of a turn of the machine.
20. In a forage harvester having a movable crop discharge spout for
directing crop to a crop-receiving wagon, a spout-aiming system
comprising:
sweep mode means for automatically and sequentially moving the
spout to a plurality of discrete sweep mode positions and for
maintaining the spout at each of said sweep mode positions for a
predetermined time period;
alignment means responsive to a predetermined spout-wagon
relationship for automatically aligning the spout with respect to
the crop-receiving wagon; and
delay means for preventing operation of the sweep mode means until
a predetermined time after termination of operation of the
alignment means.
21. In a forage harvester having a movable crop discharge spout for
directing crop to a crop-receiving wagon, a spout-aiming system
comprising:
sweep mode means for automatically and sequentially moving the
spout to a plurality of discrete sweep mode positions and for
maintaining the spout at each of said sweep mode positions for a
predetermined time period;
manually operable means for generating spout movement command
signals, the control system including means for moving the spout in
response to the oommand signals generated by the manually operable
means;
inhibit means for preventing operation of the sweep mode means when
the spout is moved outside of a predetermined range of positions in
response to the command signals generated by the manually operable
means; and
inhibit means for preventing operation of the sweep mode means
unless a predetermined delay time expires following a movement of
the spout in response to the command signals generated by the
manually operable means.
22. In a forage harvester having a movable crop discharge spout for
directing crop to a crop-receiving wagon, a spout-aiming system
comprising:
sweep mode means for automatically and sequentially moving the
spout to a plurality of discrete sweep mode positions and for
maintaining the spout at each of said sweep mode positions for a
predetermined time period;
manually operable means for generating spout movement command
signals, the control system including means for moving the spout in
response to the command signals generated by the manually operable
means; and
inhibit means for preventing operation of the sweep mode means when
the spout is moved outside of a predetermined range of positions in
response to the command signals generated by the manually operable
means.
23. In a forage harvester having a movable crop discharge spout for
directing crop to a crop-receiving wagon, a spout-aiming system
comprising:
sweep mode means for automatically and sequentially moving the
spout to a plurality of discrete sweep mode positions and for
maintaining the spout at each of said sweep mode positions for a
predetermined time period; and
means for preventing automatic movement of the spout among the
sweep mode positions when the forage harvester and wagon are
executing a turn.
24. In a forage harvester having a movable crop discharge spout for
directing crop to a crop-receiving wagon, a spout-aiming system
comprising:
sweep mode means for automatically and sequentially moving the
spout to a plurality of discrete sweep mode positions and for
maintaining the spout at each of said sweep mode positions for a
predetermined time period; and
means for preventing automatic movement of the spout among the
sweep mode positions following execution of a turn by the forage
harvester and wagon unless the wagon is substantially aligned with
the fore-and-aft axis of the forage harvester for at least a
predetermined delay time after completion of the turn.
25. In a forage harvester having a movable crop discharge spout for
directing crop to a crop-receiving wagon, a spout-aiming system
comprising:
sweep mode means for automatically and sequentially moving the
spout to a plurality of discrete sweep mode positions and for
maintaining the spout at each of said sweep mode positions for a
predetermined time period, the sweep mode positions being comprised
of a first position substantially centered with respect to the
wagon, and second, third, fourth and fifth positions, wherein the
second and fifth positions are on opposite sides of the first
position, the third position is between the first and fifth
positions and the fourth position is between the first and second
positions.
Description
BACKGROUND OF THE INVENTION
This invention relates to a control system for controlling the
position of a crop discharge spout on an agricultural machine (such
as a forage harvester) with relation to a crop-receiving wagon.
It is known to automatically align the crop discharge spout of a
forage harvester with respect to the tongue of a trailing
crop-receiving wagon to reduce crop spillage. Such systems are
described in U.S. Pat. No. 3,786,945 and in U.S. Pat. No.
4,042,132. Another such system, utilizing electro-optical devices,
is described in British patent application GBT No. 2073914,
published Oct. 21, 1981. However, the operation of such optical
devices could be adversely affected by the large amount of dirt and
debris usually present in the vicinity of a forage harvesting
machine. The system described in the published British application
includes an offset device which is comprised of an adjustable
potentiometer. It is suggested therein that this potentiometer can
be manually adjusted to achieve better side-to-side distribution of
material in the collector vehicle. However, a system which would
automatically provide even wagon filling has long been desired.
This published British application recognizes this fact and
suggests that "an automatic readjustment may be applied to produce
a periodically altering position programmed in a specific manner",
and further suggests that ". . . it may be desired slowly to dither
or oscillate the discharge spout to achieve a better side-to-side
distribution . . .". However, this British publication does not
disclose any means by which such desired automatic functions could
be achieved.
It has been suggested that even wagon filling can be obtained by
continuously sweeping the spout back and forth in an oscillatory
manner. However, such continuous sweeping requires large amounts of
energy and would increase the rate of wear of the mechanical or
hydraulic components.
It is also known to maintain the spout within distinct wide and
narrow ranges, depending upon whether the forage harvester is
traveling straight or is executing a turn, as shown in U.S. patent
application, Ser. No. 282,364, filed July 13, 1981 now U.S. Pat.
No. 4,401,403 and in U.S. patent application Ser. No. 347,125,
filed Feb. 9, 1982, now U.S. Pat. No. 4,441,846 both assigned to
the assignee of the present invention. All these aforementioned
systems utilize analog and discrete component circuitry and thus,
their functional complexity is limited by cost considerations.
Furthermore, although these systems help to prevent crop spillage,
they do not provide automatic even wagon filling because, while in
straight line travel, the spout may spend a majority of the time
directing crop to one side or the other of the wagon. Therefore, it
is desirable to make use of advanced electronics technology to
overcome this problem and to implement other desired spout-aiming
control functions.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a forage harvester
spout control system which automatically sweeps the spout during
certain conditions to uniformly fill a crop-receiving wagon.
Another object of the present invention is to prevent automatic
spout sweeping when the forage harester is executing a turn.
Another object of the present invention is to provide a
spout-aiming controller which can be easily adjusted for
crop-receiving vehicles of different sizes.
Another object of the present invention is to prevent automatic
spout sweeping when the spout is manually positioned off of the
wagon center to compensate for wind or side-hill operation.
A further object of the present invention is to provide a spout
aimer which automatically returns the spout to an edge of a wagon
crop-receiving range of positions (window) when the operator
manually moves the spout outside of this range.
An additional object of the present invention is to provide a
spout-aiming system with various self-diagnostic capabilities.
These and other objects are achieved by the present invention which
includes sensors for sensing spout and wagon position. A wagon
width potentiometer allows the control system to be adjusted for
different sized crop-receiving wagons. A programmed microprocessor
periodically samples input signals from these devices and generates
spout control command signals as a function thereof. The spout is
aimed so as to be precisely aligned with the center of the wagon
opening when the forage harvester and wagon are in a turn. A few
seconds after the vehicles have returned to straight line travel,
the spout is permitted to move within a wider range of positions. A
turn delay timer function holds the spout within the narrow range
for 15 seconds after termination of a turn to aid in spout
centering when completing gradual turns. When a manual spout
movement is made, the turn delay timer is cleared so that the spout
may be immediately maneuvered within the wide range. This permits
the operator to manually position the spout to a side of the wagon
opening to compensate for wind or side-hill operation.
When the operator points the spout outside the opening, the
controller will automatically return the spout to the edge of the
wagon opening upon completion of the manual movement.
When the wagon is in line with the forage harvester, the 15 second
turn delay time period is expired and the spout is aimed at the
central 25% of the wagon opening, then the controller will
autmomatically enter a sweep mode. In the sweep mode, the spout is
moved stepwise through a sequence of 5 positions across the wagon
opening to evenly fill the wagon. The consecutive positions are on
alternate sides of the wagon center and the spout remains at each
position for a predetermined time, such as 15 seconds. A sweep mode
software counter is incremented every time an automatic spout
movement is made so that the spout will normally move to a
different one of the five positions each time the sweep mode
operation is begun. Manual movement of the spout disables the sweep
mode until the spout is automatically or manually returned to the
central 25% of the window and the other sweep mode conditions are
satisfied.
If the wagon is moved beyond plus or minus 55 degrees from the
in-line position, the spout is stopped at the angle corresponding
to an angle of plus or minus 55 degrees. This prevents excessive
spout rotation when the wagon tongue is in the stowed position or
is moving freely.
If the spout has been rotated under manual control to a position
beyond the range of the spout position sensor, the microprocessor
detects a wrap-around condition. When this occurs, the automatic
spout aimer will rotate the spout back through the "end of range"
on the sensor and return the spout to the normal position. This
feature will work for excessive manual rotation in either
direction.
Hydraulic valve shut-off time and inertia in the hydraulic motor,
spout, etc. cause the spout to continue moving for a few degrees
after valve electric power has been shut off. The automatic spout
aimer compensates for this by shutting the valve off early and
coasting the spout into the target position.
If the wagon tongue sensor fails or is rotated to the "end of
range" area of the potentiometer, a pair of electronic module
"tongue" lights will come on and the automatic spout aimer will
cease operating. Similarly, if the spout sensor fails or the spout
is rotated to the sensor "end of range" area, a pair of "spout"
lights will come on and the automatic spout aimer will try to move
the spout out of the "end of range" area. After four seconds, it
will stop operating if the pot does not come out of the "end of
range" area. If the input multiplexer or output relays in the
electronic module fail, the "tongue" and "spout" lights will
alternately flash, indicating an electronic module failure.
A noisy or erratic spout sensor producing intermittent voltages
will not confuse the automatic spout aimer. The first derivative is
taken on the sensor input data and the information is discarded if
the rate of change exceeds the normal maximum.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration depicting a typical agricultural machine,
such as a forage harvester, pulling a crop-receiving wagon;
FIG. 2 is a simplified schematic representation of the control
system of the applicants' spout aiming control system;
FIG. 3 is a detailed circuit schematic of the auto control unit of
FIG. 2;
FIGS. 4a-4p are logic flow diagrams of the control algorithm
executed by the microprocessor of FIG. 3;
FIG. 5 is a logic flow diagram of a routine executed during
operation of the algorithm of FIGS. 4a-4p;
FIG. 6 is a schematic representation of the sweep mode positions of
the spout;
FIG. 7 is a logic flow diagram of a check limit and output command
routine executed during operation of the algorithm of FIGS. 4a-4p;
and
FIG. 8 is a logic flow diagram of a manual operation test routine
executed during operation of the algorithm of FIGS. 4a-4p.
DETAILED DESCRIPTION
As seen in FIG. 1, a tractor-drawn forage harvester 10, or a
self-propelled forage harvester (not shown), includes a
conventional drawbar which is hidden from view by a rotatable
forage dispensing spout 14. The tongue 16 of a wagon 18 is hitched
to the drawbar so that the wagon 18 receives the material
discharged from the spout 14. A spout angle is defined as the
relative angle between the spout 14 and the fore-and-aft axis of
the harvester 10. A tongue angle is defined as the relative angle
between the wagon tongue 16 and the fore-and-aft axis.
A control system 22, schematically shown in FIG. 2, controls the
position of the spout 14, either automatically or manually, via a
known electrohydraulic circuit 24, which is currently used in
production forage harvesters to move the spout 14 left or right.
Circuit 24 includes a conventional bi-directional fluid motor 26
for rotating the spout 14 either left or right, viewing FIG. 1, in
response to fluid received from pilot-operated directional control
valve 28, connected to a pump-fed pressure line 30 and a tank line
32. Left and right solenoid-operated pilot valves 34 and 36 operate
the directional control valve 28 in response to control signals
applied to left and right control lines 38 and 40, respectively.
For operating with an open-center hydraulic system, (not shown),
circuit 24 includes an optional pilot-operated bypass valve 42
controlled by solenoid-operated valve 44 which receives control
signals via control line 46. It should be noted that it is within
the scope of this invention to substitute an electric powered motor
for the hydraulic motor 26 and an electric control circuit for the
hydraulic circuit 24.
A manual directional control switch module 50 includes a double
pole, double throw momentary-type switch 51 with one side of both
poles connected to the +12 volt terminal of the vehicle battery or
power supply. Left and right switch contacts 52 and 54 are
connected to left and right input or control lines 38 and 40,
respectively. Optional open center contacts 56 and 58 are both
connected to control line 46 so that valve 44 is actuated to close
bypass valve 42 whenever switch 51 is in contact with contacts 52
or 54.
Referring now to FIG. 3, the spout angle sensor 60 and the tongue
angle sensor 62, both preferably consist of conventional rotary
potentiometers (pots) connected to generate voltages indicative of
the spout angle and the tongue angle, respectively. In the case of
a non-towed, crop-receiving wagon, a wagon position signal could be
obtained by the use of an optical wagon position sensing system,
such as described in the aforesaid published British Application,
No. 2,073,914. The spout angle voltage generated by spout angle
sensor 60 may be considered to be the feedback signal for the
automatic control circuit 64. The automatic control circuit 64
generates left and right control signals in output lines 66 and 68
and in output line 70, as a function of the position of the tongue
and of the spout. Output lines 66, 68 and 70 are connected to
control lines 38, 40 and 46, respectively. Spout and tongue angle
sensors 60 and 62 are connected to inputs of a conventional
multiplexer 72. Potentiometers 74, 76 and 78 are also coupled to
input pins 1, 5 and 2 of the multiplexer 72 and provide adjustable
calibration signals that will be explained later.
The spout and tongue pots preferably have zero to full-scale
resistance ranges which span over 340 degrees and with deadband
ranges of 20 degrees. The resistance ranges are positioned so that
one-half of the full scale resistance corresponds to a
straight-back spout or tongue position. Furthermore, for diagnostic
purposes, a pair of points within the full scale resistance ranges,
one being approximately 5 degrees from the zero resistance point,
the other being approximately 1 degree from the full scale
resistance point, are used to define the boundaries of "electrical"
or "working" ranges of the potentiometer.
The spout potentiometer 60 is preferably gear-coupled to the spout
so that a spout position angular range of approximately 143 degrees
corresponds to the pot full scale resistance range or "working
range" of 334 degrees. Thus, the "working" range for the spout pot
60 corresponds to a range of spout positions of approximately 140
degrees. The tongue pot, 62, however, is directly couple to the
tongue 16 so that there is a 1:1 relationship between the tongue
angle range and the angle range of the tongue pot 62. The
relationship of the signals from the potentiometers 60 and 62 to
values corresponding to this "electrical" range is examined to
determine whether potentiometer error flags, or a spout wrap-around
error flag, should be generated. This is further described later
herein with reference to steps 294, 302 and 304-336 of a
microprocessor program, for example.
Pull-up and pull-down biasing resistors (not shown) are connected
to the wipers of potentiometers 74, 76 and 78. For spout and tongue
calibration potentiometers 74, 76, these biasing resistors are
chosen so that in the event of an open circuit condition in the
wiper lead, the voltages received by the multiplexer 72 will
correspond to a centered calibration adjustment. For the wagon
width potentiometer 78, the biasing resistors are chosen so that
the wiper open circuit voltage will correspond to the normal width
of a typical wagon.
The multiplexer 72 feeds selected signals to the analog input ANO
of a microprocessor (micro) 80. The micro 80 includes a central
processing unit, ROM program memory, a RAM data memory and input
and output ports. In general, the microprocessor ROM stores
instructions, which comprise the coded information that controls
the activities of the central processing unit. The microprocessor
RAM stores the coded data information processed by the central
processor unit. The central processor unit reads each instruction
from the program memory according to a predetermined sequence in
order to control its data processing activities. The microprocessor
program, which will be described later, is represented by the flow
charts of FIG. 4a-4p, 5, 7 and 8.
The control signals generated by the microprocessor 80 are applied
to the address inputs (not shown) of the multiplexer 72, to relay
drivers 82 and 84, and to LED drivers 85, 86, 87 and 88. The LED
drivers drive corresponding left and right spout indicator lights
105 and 106 and left and right tongue indicator lights 107 and 108,
which are preferably located on an operator observable panel. Relay
drivers 82 and 84 drive relays 90 and 92, respectively, in response
to control signals generated at micro outputs P10 and P11 to
operate respective pilot valves 36 and 34 of circuit 24. Diodes D1
and D2 provide for energization of relay 94 and pilot valve 44
whenever either of relays 90 and 92 is energized. Diode D3 provides
a path for inductive fly-back current from relay 94. Although not
shown, it can be assumed that drivers 82 and 84 include similar
fly-back diodes.
The anodes of diodes D1 and D2 are respectively connected to relay
sensing inputs P04 and P05 of the micro 80 via identical voltage
limiting and filtering circuits 96 and 98. Circuit 98 is shown in
detail and includes resistors R1, R2 and R3, a zener diode D4 (such
as an IN4735) and capacitor C1 connected as shown. Through circuits
96 and 98, the micro 80 senses energization of lines 66 and 68,
either manually due to operation of switch 51 or automatically due
to signals generated at micro outputs P10 and P11. The circuits 96
and 98 protect the micro 80 from high voltages and transients.
Jumper circuits 100 and 102 and a switch 104 may be coupled to the
micro 80 so that by opening or shorting various ones of the
jumpers, the operation of the circuit 64 can be adapted for
specific situations. For example, a spout sweep mode of operation
may be enabled or disabled by opening or closing, respectively,
switch 104.
The control algorithm will now be described with reference to the
flow chart shown in FIGS. 4a-4p, 5, 7 and 8. The algorithm begins
at step 202 in response to a hardware reset or upon an external or
timer interrupt. At steps 204-208, the external interrupt and the
timer interrupt are disabled and the random access memory (RAM) is
cleared. In step 210, a hardware timer (not shown) which is
integral to the micro 80, is initialized. This hardware timer
periodically generates a flag signal (every 80 milliseconds, for
example) which is used to obtain a desired time interval for use
with the software timers described later.
In step 212, a turn delay software timer and a sweep mode delay
software timer are started. Then, in step 214, the spout position
or angle is read from sensor 60. In step 216, left and right
"undershoot" registers are initialized to values representing 3
degrees, which is initially assumed to be the amount of spout
over-travel.
The main loop begins with a manual operation test routine 217. This
manual operation test routine (which is described in detail with
reference to FIG. 8) sets or clears a manual flag, depending upon
whether or not any signals at relay sense inputs P04 or P05 are due
to manual operation of switch module 50.
After the manual test routine, the algorithm proceeds to step 218
which directs the algorithm to step 268 if the hardware timer flag
is not set, otherwise, the algorithm proceeds to steps 220-226
where the turn delay timer and the sweep mode delay timer are
decremented unless they are already decremented to zero.
The turn delay timer (timer 1) is used to maintain the spout at a
target position closely aligned with the center of the wagon and to
prevent operation of the sweep mode until 15 seconds expire after
the forage harvester completes a turning operation (see steps 378,
384, 386 and 406). This assures that the wagon will be closely
aligned with respect to the fore and aft axis of the forage
harvester before the spout is allowed to be misaligned by a larger
angle from the center of the wagon.
The sweep delay timer (timer 2) is used to maintain the spout at
each sweep mode position for 15 seconds (see steps 508, 516, 528)
and to prevent operation of the sweep mode until 15 seconds after
completion of a manual or automatic spout movement (see step 482)
which places the spout in the central 25% of the crop-receiving
window.
In steps 228-232, a display timer (timer 3) is decremented (230) or
reinitialized (232), as directed by step 228, in order to provide a
data bit which toggles at a 1-2 Hz rate for use in triggering a
flashing display device (not shown). Steps 234-236 decrement a
relay delay timer (timer 4) for use in relay diagnostics.
Step 237 determines whether a spout pot error flag has been set, as
in step 312. If not, the algorithm proceeds to step 238. However,
if yes, then the algorithm is directed to step 237A which
decrements a 4 second timer (timer 5), or "spout pot error delayed
timer", which is started in step 312. Then, step 237B directs the
algorithm to 238 if the timer 5 has not expired, otherwise, the
algorithm proceeds to step 237C which sets a "spout pot error
delayed flag". Thus, the "spout pot error delayed flag" is not set
unless a spout pot error flag (set in step 312) is continuously set
for 4 seconds.
Step 238 directs the algorithm to step 240 if an undershoot delay
timer (timer 6) is running. Otherwise, the algorithm is directed to
step 246. The timer 6 preferably has a duration of approximately 1
second and is started when the spout is instructed to stop moving
(see step 508). The undershoot delay timer is used to delay
recalculation of the right and left undershoot values, UNDR and
UNDL, in step 504 until the spout has had enough time to coast to a
stop following an automatic spout movement. Step 240 decrements the
undershoot delay timer, whereupon in step 246, the hardware timer
is reinitialized. After step 246, the manual operation test routine
of FIG. 8 is repeated at step 268.
Step 270 clears a multiplexer error flag. Then, steps 272-278
operate to set a multiplexer error flag in step 278 if input pin 4
of multiplexer 72 is not properly grounded, if the voltage on input
pin 12 of multiplexer 72 and at the threshold input, Vth, of micro
80, is not 2 volts, or if the voltage at pin 13 of multiplexer 72
is not 5 volts. Otherwise, the algorithm proceeds to step 286. The
grounded input (pin 4) of multiplexer 72 and the 5-volt input (pin
13 of multiplexer 72) are chosen such that the address code of one
is "all ones" and the address code of the other is "all zeroes".
Thus, the address codes corresponding to ground and 5-volts will be
incorrect if the addressing mechanism is not working correctly. In
this manner, certain self-diagnostic functions are performed.
First, the operation of the analog-to-digital converter (part of
micro 80) is verified. Second, the operation of the addressing
mechanism between micro 80 and multiplexer 72 is tested.
In steps 286 through 292, values are read from the spout
calibration potentiometer 74, tongue calibration potentiometer 76,
wagon width potentiometer 78 and the tongue position sensor 62.
Then, step 294 directs the algorithm to step 302 where a tongue pot
error value is set, and then to 303, if the tongue position value,
TPTONG, from 292 corresponds to a value which is outside of the 334
degree electrical range of the tongue pot 62. Since the tongue is
normally physically prevented from moving to positions beyond 90
degrees of straight back, very low or full scale tongue pot values
can be interpreted as being due to a failure of the tongue
potentiometer. Otherwise, step 294 directs the algorithm to step
296 where the tongue pot error is cleared. Then, at 298, the tongue
position value, TPTONG, (from step 292) is modified by the tongue
calibration value according to the statement
TPTONG=TPTONG+(TCAL.div.8), where TCAL is the tongue calibration
value from calibration pot 76. At step 300, if the TPTONG value is
greater than +55 degrees or less than -55 degrees, the TPTONG value
is set equal to +55 degrees or -55 degrees, respectively. This
prevents excessive spout rotation when the tongue is freely
swinging or stowed.
The manual operation test routine of FIG. 8 is repeated at step
303. At step 304, a spout angle or position valve, TSPOU, is
obtained from spout angle sensor 60. Then, step 306 directs the
algorithm to step 338 if the difference between the current and
previous signals representing the spout angle is greater than a
threshold value which would correspond to a spout angular velocity
of, for example, 18 degrees per second. Since the spout normally
moves slower than this angular velocity, rapidly changing spout pot
values are an indication that the spout has rotated out of the
electrically operative or "working" range of the spout pot 60.
Thus, step 306 detects when the spout rotates past the electrically
operative range of potentiometer 60, which would cause an abrupt
change in the signal produced by spout pot 60. In this case, the
old spout position value is utilized since the algorithm proceeds
directly from step 306 to step 338, thus skipping step 334, where
the spout position value would normally be readjusted. Otherwise,
the algorithm proceds to step 308 which directs the algorithm to
step 314 if a spout pot error flag has previously been set by step
312. If not, the algorithm proceeds from step 308 to 310. Step 310
directs the algorithm to step 320 if the signal from spout pot 60
is within its 334 degree "working" range. Otherwise, the algorithm
proceeds to step 312. Thus, step 312 sets a spout pot error flag
and starts the spout pot error delay timer running if the signal
from spout pot 60 is outside the 334 degree "working" range. After
step 312, the algorithm proceeds to step 328.
Step 320 directs the algorithm to step 328 if a wrap error flag has
been set (by step 324). Otherwise, the algorithm proceeds to step
322 where a PREHEM value is stored to indicate whether the spout
pot 60 was last in the high half of its resistance range or in the
low half of its resistance range. After 322, the algorithm proceeds
to step 328.
If step 308 directs the algorithm to step 314, then step 314
determines if the sensed spout pot 60 is within the 334 degree
"working" range. If not, the algorithm proceeds to step 328. If so,
it means that the spout pot 60 has returned to a position within
the 334 degree working range, and the algorithm proceeds to step
316 which determines whether the signal from spout pot 60
corresponds to a spout pot position within the same hemisphere
which it was previously within. If not, it is indicated that the
spout has continued rotating out of one hemisphere of the working
range of the spout pot 60 and then back into the other hemisphere
without passing through the spout centered position, and then a
wrap error flag is set in step 324. If yes, it means that the spout
pot 60 has re-entered the working range in the same hemisphere in
which it left the range by reversing its direction of rotation,
whereupon the wrap error flag is cleared in step 318. After steps
324 or 318, the spout pot error and the spout pot error delayed
flags are cleared in step 326. Thus, by keeping track of whether
the spout is within its 344 degree working range and of which
hemisphere spout pot 60 is in, the control system can determine
when the operator has manually moved the spout 14 outside of its
normal centered 140 degree working range and will return spout 14
toward the crop-receiving wagon in the proper direction.
Step 328 determines whether a wrap error or a spout pot eror flag
has been set. If yes, it means that the spout pot 60 is either not
within its working range or has wrapped around from one hemisphere
to the other without going through the spout centered position and
the algorithm proceeds to step 330. Step 330 determines if the
spout was previously in the right hemisphere. If so, the spout 14
must now be beyond 70 degrees right of center and step 336 sets the
actual spout position value, TSPOU, to a value corresponding to a
spout position at the end of the electrical range of the spout pot
60 (spout 14 is 70 degrees right of center). If not, spout 14 must
now be beyond 70 degrees left of center and step 332 sets the
actual spout position value, TSPOU, to a value corresponding to a
spout position at the end of the electrical range of the spout pot
60 (spout 14 is 70 degrees left of center). Thus, one of the spout
position values set in steps 332 or 336 is used whenever the spout
has "wrapped around", and a wrap error flag is set in step 328.
However, if there is no wrap error, as is the case during normal
operation, then step 328 directs the algorithm to step 334 where
the actual spout position value, TSPOU, is adjusted according to
the statement: TSPOU=TSPOU+(SCAL.div.8), where SCAL is the spot
calibration value from spout calibration potentiometer 74.
If step 306 detects that the signal spout pot 60 was changing
faster than a certain rate due to rotating of the spout out of the
electrical range of the spout pot 60 or due to an electrical
failure of the spout pot 60, then the algorithm is directed
directly to step 338, the spout position value is not updated or
adjusted by steps 332, 334, or 336 and the rest of the algorithm
operates with the previous spout position value.
It should be noted that during normal operation, (when the spout
neither moves too fast nor wraps around, nor remains outside of the
140 degree working range), the algorithm will proceed through steps
306, 308, 310, 320, 322 and 328 to step 334, where the sensed spout
position value, TSPOU, is recalculated.
After steps 332, 334 and 336, or from step 306, the algorithm
proceeds to step 338 which determines whether the relay delay timer
(described with reference to previous steps 234 and 236) is
running. If yes, it means that not sufficient time has expired to
allow signals to return to relay sensing inputs P04 and P05 of the
micro 80, and the algorithm skips ahead to step 344. If not, then
it means that relay status signals should have been received by
micro inputs P04 and P05 and the algorithm is directed to step
340.
Steps 340-346 check the activation of relays 90 and 92 by comparing
the signals at micro output command ports P10 and P11 with the
signals at micro relay sense ports P04 and P05 and by generating or
clearing a relay error flag according to the following rules.
A relay error flag is set in step 346 only when either port P10 or
P11 is low and the corresponding port P04 or P05 is low; otherwise,
the relay error flag is cleared in step 344. This provides an
indication that a relay activation signal was generated, but that
due to some failure, the corresponding relay was not energized. At
the same time, a relay sense signal caused by a manual spout-moving
operation is not interpreted as a failure.
The manual test routine of FIG. 8 is repeated at step 347.
Next, step 348 determines whether the multiplexer error flag was
set in step 278 or the relay error flag was set in step 346. If
yes, then the algorithm proceeds to steps 362-366 which operate
over successive cycles of the routine to alternately flash the
spout and tongue indicator lights 105-108. The lights 105-108 are
flashed in response to the changing of a bit which is controlled by
timer 3 (see steps 228-232). After steps 364 or 366, the algorithm
proceeds to step 374. If no relay or multiplexer error flags have
been set, then step 348 directs the algorithm to step 350.
Step 350 determines if a spout pot error flag has been set by step
312. If so, then both the left and right spout lights 105 and 106
are turned on by step 354 to indicate this condition to the
operator. If not, then step 352 turns on one of the left or right
spout lights if the spout 14 is left or right, respectively, of its
centered position. Step 352 will turn both spout lights off if the
spout is centered.
Step 356 determines whether a tongue pot error flag has been set by
previous step 302. If so, then both tongue lights 107 and 108 are
turned on by step 360 to indicate this condition to the operator.
If not, then step 358 turns on either the left or the right tongue
light if the tongue 16 is left or right, respectively, of its
centered position. Step 358 will turn both tongue lights off if the
tongue is centered.
In step 374, a "WORK" or "scratchpad" value is set equal to the
absolute value of the angle of the tongue 16 with respect to its
centered position. Then, step 376 compares the WORK value to a wide
tongue angle threshold value, WIDE, of 12 degrees, for example. If
WORK is greater than WIDE, then it means that the forage harvester
and wagon are in a turn and the algorithm is directed to step 384
which starts the turn delay timer (timer 1). The turn delay timer
is used to measure a predetermined time period and is repeatedly
started by step 384 as long as the vehicles remain in the turn so
that the turn delay timer will not expire until a predetermined
time after the vehicles have come out of the turn. If WORK is not
greater than WIDE, then it means that the vehicles are not in a
turn and the algorithm proceeds to step 378. If the turn delay
timer is still running, then step 378 directs the algorithm to step
386 which sets the hysteresis flag. Thus, the hysteresis flag is
set in step 386 so that step 406 will cause a skip ahead to step
414 and will maintain the spout in the more closely tongue aligned
position until a predetermined time after the vehicles have come
out of a turn.
If the turn delay timer is not running, then step 378 directs the
algorithm to step 380, which determines whether the WORK value is
greater than a narrow tongue angle threshold value, NARROW, such as
9 degrees. If yes, it means that the vehicles are still in a turn
and the algorithm skips ahead to step 387. If not, it means that
the vehicles have come out of a turn and the hysteresis flag is
cleared and a power-up (PWRUP) flag is set at step 382 for use in
later described step 496.
In step 387, the manual operation test routine FIG. 8 is
repeated.
In step 388, a desired spout position value, SPOUTN, is calculated
as a function of the sensed tongue position by the equation:
SPOUTN=M1.times.TPTONG+B1, wherein M1=0.805, TPTONG is the tongue
position value (from sensor 62) and B1=0. This SPOUTN value in 388
is continuously updated and stored in a first desired spout
position value register (not shown). These "M" and "B" values, and
the ones which follow, are only exemplary and would vary for
different vehicles.
In step 390, the manual operation test routine of FIG. 8 is
repeated.
Then, in step 400, the WORK value is again set equal to the
magnitude of the distance between the actual tongue position,
TPTONG, and the center tongue position.
Then, in step 402, a spout position limit value, DLIMIT, is
calculated from the equation: DLIMIT=(M2.times.WORK)+B2, where
M2=0.0 and B2=4.0. The DLMIT value is added to and subtracted from
the desired spout position value in steps 418 and 420 to provide
the upper and lower limit values of a narrow target range of
permitted spout positions about the desired position.
Then, in step 404, a decreased manual range value, DFMO (for use if
the spout is under manual control) is calculated from the equation:
DFMO=(M4.times.WORK)+B4, where M4=0.083 and B4 =19.
Then, step 406 determines whether the hysteresis flag was set (as
in step 386) to indicate that the vehicles are turning. If so, the
algorithm is directed to step 414. If not, the algorithm proceeds
to step 408 where a maximum wide range value, ALIMIT is calculated
by the equation: ALIMIT=M3.times.WORK+B3, where M3=0.083 and B3=22
are factors related to the geometry of the machine system.
Next, in step 410, the maximum wide range value, ALIMIT, is scaled
as a function of the wagon window size, as represented by the
setting of wagon width potentiometer 78, according to the equation:
ALIMIT=(TPWDT.times.ALIMIT)-256, where TPWDT is a value
representing the wagon width provided by wagon width potentiometer
78. TPWDT has a range of 0 to 255 so that ALIMIT is scaled by
between 0 and 1. Thus, all values derived from the ALIMIT value in
step 410 can be modified or scaled by adjusting the wagon width
potentiometer 78.
Then, step 412 sets the DLIMIT value equal to the larger of the
spout position limit value, DLIMIT, and of the maximum wide range
value, ALIMIT.
Then, steps 414 and 416 cause the DLIMIT value to be decreased by
the DFMO value if the spout is under manual control. Otherwise, the
algorithm proceeds from step 414 to 418. This DLIMIT value from
step 402, 412 or 416 is then added to and subtracted from the
desired or nominal spout position value, SPOUTN, to provide high
and low spout position range end point values, LIMHI and LIMLO, in
steps 418 and 420, respectively. These LIMHI and LIMLO values
represent the edges of a wagon-defined, crop-receiving,
spout-position range. Thus, steps 388-420 establish a target range
of spout positions centered about a nominal or desired position.
The width of this target range depends upon the wagon width, upon
whether the spout is under automatic or manual control, and upon
whether the vehicle is turning or has recently completed a
turn.
Thus, when the forage harvester is not in a turn, no automatic
spout position correction is made until the spout position deviates
from the tongue by at least +22 degrees. This +22 degree range is
represented by the LIMHI and LIMLO values in steps 418 and 420,
using the wide range ALIMIT value set in steps 408 and 410,
unmodified by step 416. This 22 degree value results from the B3=22
value in step 408. The spout is then repositioned to a desired
position represented by the TARGET value in step 428 or 430, due to
operation of steps 490-514.
However, when the forage harvester is in a turn, a spout position
correction will be made when the spout position deviates from the
tongue by only 4 degrees. This narrower 4 degree range is
represented by the LIMHI and LIMLO values in steps 418 and 420
using the DLIMIT value from step 402, without modification in steps
408-412. The 4 degree value results from the B2=4 value in step
402. This is because step 406 causes steps 408-412 to be bypassed
when the forage harvester is in a turn.
Similarly, after the spout is manually moved, no automatic spout
position correction will be made unless the spout position deviates
from the tongue by 19 degrees. This is because the LIMHI and LIMLO
values in step 418 and 420 will be derived using the modified
ALIMIT value of step 416 when under manual control. The 19 degree
value results from the B4=19 value in step 404. Furthermore,
because of steps 440-482, the spout will be repositioned only to
just within this +19 degree range, rather than to the closely
tongue-aligned TARGET position. This permits the operator to
manually position the spout to one side or the other without having
the spout automatically repositioned back to the closely
tongue-aligned position represented by the TARGET value. This is
useful during windy or side-hill conditions.
Step 422 then determines whether the sweep mode flag is set to
indicate that the spout position sweep mode (wherein the spout is
automatically and sequentially moved through a series of positions)
is active. If not, the algorithm proceeds to step 424. If yes, the
algorithm proceeds to a routine represented by step 423 and shown
in detail in FIG. 5, wherein the desired spout position value,
SPOUTN, is redetermined to correspond to the next sweep mode
position.
Referring now to FIG. 5, first the contents, N, of a modulo five
software sweep step counter (which is decremented in step 504 of
the main algorithm) is examined in step 540. Then, depending upon
the sweep step counter value, N, the next desired spout position
value, SPOUTN, is established in the corresponding one of steps
550-554. For example, if N=0, then the algorithm proceeds to step
424 using the previously established SPOUTN value. If N=1, 2, 3, or
4, then differential values d1 or d2 are added or subtracted to
obtain the new desired SPOUTN value. The differential values d1 and
d2 are defined as follows:
d1=(DLIMIT-DFMO).times.3/4
d2=(DLIMIT-DFMO).times.3/8.
In this manner, in the sweep mode, the SPOUTN value will assume one
of five different values, one representing a spout position
substantially centered with respect to the wagon tongue and the
others representing a pair of spaced-apart positions arranged on
either side of the centered position. The dl and d2 values are
chosen so that the spout sweep mode positions will typically be
spaced approximately 7 and 15 degrees on either side of the spout
centered position. It should be noted that this exemplary spacing
will be varied in response to adjustment of the wagon width
potentiometer 78 due to the operation of steps 410 and 412. Note
also that as the sweep mode counter value N is decremented, the
spout positions will alternate from the left and right sides of its
centered position, as illustrated in FIG. 6.
Returning now to FIG. 41, step 424 determines whether the spout is
being moved automatically by the micro 80. If yes, the algorithm
proceeds to step 425 which directs the algorithm to 430 if the
spout is moving to the left, otherwise, to step 428. If the answer
in 424 is no, then the algorithm is directed to step 426.
In step 426, a current sensed or actual spout position value,
TSPOU, which is derived from the spout position potentiometer 60,
is compared to the desired spout position value, SPOUTN. If TPSPOU
is greater than SPOUTN, then 426 directs the algorithm to step 430,
otherwise, to step 428. Thus, depending upon whether the spout 14
is approaching its desired position from the right or from the
left, a TARGET value is calculated in step 428 or 430,
respectively, wherein right and left undershoot values, UNDR and
UNDL, (equal to one-fourth of the values determined in step 504) is
subtracted from or added to the SPOUTN value, respectively. Thus,
the SPOUTN value is modified by an undershoot factor which is
chosen so that if the spout moving relays 90 or 92 are turned off
when the spout 14 reaches the position represented by the TARGET
value, then the inertia of the spout 14 will carry it just to the
desired spout position represented by the SPOUTN value.
Step 432 determines whether any "fatal" error flags have been set
in steps 302, 237C or 278. If yes, then the algorithm proceeds to
step 438, otherwise the algorithm is directed to step 440. Step 438
turns off the relays 90-94 and returns the algorithm to the "main
loop start" at step 217.
At this point, it is appropriate to summarize the operation of this
system with respect to spout pot and wrap-around errors. When the
spout moves out of electrical range of the spout pot 60, both spout
lights are turned on in step 354 due to the operation of steps 310,
312 and 350. If the spout pot error flag (set in 312) is not
cleared before expiration of the spout pot error delay timer
(started in step 312), then all relays are turned off due to the
operation of steps 237C, 432 and 438. However, under the normal
manually-induced wrap-around situation, the spout pot error flag
will be cleared in step 326 before the spout pot error delay timer
can expire, and step 432 will prevent step 438 from forcing the
relays off. Note that the display is immediately controlled by the
spout pot error flag. However, the relays are controlled by steps
432 and 438 in response to the spout pot error delayed flag.
Step 440 determines if a manual flag was set by any of the manual
test routines in response to a manual activation of switch 51. If
not, the algorithm proceeds to steps 490-514 which define an
automatic operational strategy, otherwise the algorithm proceeds to
steps 442-486 which define a manual operational strategy.
In the manual strategy algorithm portion, step 442 determines
whether the spout is moving in response to manual actuation of
switch 51 or whether the spout is moving in response to command
signals generated at outputs P10 and P11 of micro 80. If micro
outputs P10 and P11 are not causing the spout movement, then the
algorithm is directed to step 444 (FIG. 4n) which determines
whether an "AUT02" flag has been set, as by step 460 immediately
following termination of manual activation of switch 51. If the
"AUT02" flag is not set, the algorithm proceeds to step 446 which
determines whether switch 51 is still engaged (as indicated by the
presence of a relay sense signal at relay sense input P04 or P05).
If yes, step 446 directs the algorithm back to the main loop start
at 217 so that the manual movement of the spout via switch 51 may
continue. If no, then it means that the operator has ended
actuation of switch 51 and step 446 directs the algorithm to a
"check limit" represented by 448 and which will be described later
with reference to FIG. 7. Briefly, this routine generates a "stop"
command if the spout is positioned within a wagon crop-receiving
range of positions. Routine 448 will also generate "move left" or
"move right" commands, depending upon which way the spout must be
moved to return to this crop-receiving range. If the spout is
outside the crop-receiving range, then the command will be "move
left" or "move right", and step 450 will direct the algorithm to
step 452 which clears a "MANTOU" flag and sets the "AUT02" flag.
However, if the command generated by the routine of 448 is "stop",
it means that the spout was manually moved, but not out of the
crop-receiving range, and the algorithm is directed by step 450 to
step 460. Step 460 sets the "AUT02" flag, starts the undershoot
delay timer and starts the sweep mode delay timer.
After step 452, then step 454 determines whether the spout is out
of the crop-receiving range by more than a certain distance. This
certain distance is preferably defined as a distance represented by
the sum of the distances represented by the LIMHI or LIMLO values
and the undershoot values, UNDR or UNDL. If the spout position is
out of the crop-receiving range by more than this certain distance,
then this is defined as a "long move" situation and step 454
directs the algorithm to step 456 where this situation is indicated
by the setting of the "MANTOU" flag. Otherwise, the algorithm
proceeds directly to step 458 which starts the relay delay timer,
after which the algorithm returns to step 217. The relay delay
timer is started so that step 338 will prevent checking of the
relays (by step 340) during future executions of the algorithm
while the spout is starting to move.
Returning to step 444, if the AUTO 2 flag was set (as will be done
by step 460 upon termination of a manual activation of switch 51),
then the algorithm is directed to step 462. Step 462 determines
whether the MANTOU flag was set, (indicating a "long move"
situation). If yes, the algorithm proceeds to step 464 where the
limit values LIMHI and LIMLO are adjusted by their corresponding
undershoot values. Otherwise, the algorithm proceeds directly to
step 466 which again performs the routine referred to by previously
described step 448 and described in detail with respect to FIG. 7.
After the appropriate spout movement commands are generated at step
466, then step 468 determines whether the spout is moving. If yes,
the algorithm returns to step 217 while the spout movement
continues. Once the spout has stopped moving, after termination of
manual activation of switch 51, the algorithm proceeds to step 470
which determines if the undershoot delay timer (started in step
460) has expired. If not, the algorithm returns to step 217. In
this manner, the undershoot delay timer prevents updating of the
undershoot values until 1 second after termination of an automatic
spout movement, and delays re-examination of the spout position by
the automatic operating strategy until the spout has had time to
come to rest after a manual movement. This allows for the spout to
be automatically brought back into the crop-receiving "window" when
the manual switch is released when the spout is just within the
"window", but the spout inertia carries it out of the "window". If
yes, the algorithm proceeds to step 472 which clears the MANUAL,
MANTOU and AUT02 flags to indicate the termination of a manual
spout movement and the absence of a "long move" situation. After
472, the algorithm returns to step 217.
Returning now to step 442 (FIG. 4m), if the micro is moving the
spout (such as when the spout is automatically moved back into the
crop-receiving range after a manual movement of the spout out of
that range), then step 442 directs the algorithm to step 474 which
determines whether the MANTOU flag is set. If yes, it means that a
"long move" situation exists and the algorithm proceeds to step 476
where the LIMHI and LIMLO values are adjusted by the undershoot
values. Otherwise, step 474 directs the algorithm directly to step
478. Step 478 is identical to the routine illustrated in FIG. 7
except that step 710 (output commands) of this routine is
eliminated from the routine performed at step 478. Then, step 480
performs the same determination which was previously described with
respect to step 450 so that if "move right" or "move left" commands
result from step 478, then the algorithm is returned to step 217.
Otherwise, the algorithm proceeds to step 482 where a stop movement
command is generated, the relay delay timer is started to prevent
the erroneous detection of manual operation in step 802, the
undershoot delay timer is started to prevent the initiation of an
automatic spout movement until the spout has stopped coasting, and
the sweep mode delay timer is started (to prevent sweep mode
operation until a certain time after termination of a manual spout
movement). After step 482, the algorithm returns to step 217.
This manual control portion of the algorithm assures that the spout
remains in or will be returned to the wagon crop-receiving range of
positions after termination of manual spout movement via switch
51.
Returning now to step 440 (FIG. 41), if the manual flag was not
set, then the algorithm is directed to the automatic operating
strategy portion of the algorithm of steps 490-514 (FIGS. 4o and
4p). Step 490 directs the algorithm to step 492 if the AUTO flag is
set. Step 492 determines whether the AUT02 flag has been set (as in
step 508). If yes, the algorithm proceeds to 494, otherwise to 506.
Step 494 determines whether the undershoot delay timer is running.
If yes, the algorithm is directed to step 496 which determines
whether the PWRUP flag is cleared. Since the PWRUP flag is
initially cleared upon start-up and is not set in step 382 until
the turn delay timer has expired, step 496 will prevent automatic
spout movement upon start-up until the undershoot delay time has
expired (494) and the undershoot values are updated at step 504. If
the PWRUP flag has been set (as at step 382), then the algorithm
proceeds to step 498 where the LIMHI and LIMLO values are modified
by the undershoot values UNDR and UNDL. Then, in step 499, the
check limit routine consisting of steps 700- 708 of FIG. 7 is
executed. Then, in step 500, if a "stop movement" command is
generated in step 499, step 500 returns the algorithm to step 217.
If a "move right" or "move left" command is generated, then the
algorithm proceeds to step 502. Step 502 outputs the generated move
command to the micro output P10 or P11 so that the desired
automatic spout movement is performed. Step 502 also clears the
AUT02 flag, clears the undershoot delay timer (so that a new
undershoot value will not be calculated until the spout stops
moving) and starts the relay delay timer (to prevent checking of
relay sense inputs P04 and P05 until a short time after spout
movement has started. After 502, the algorithm returns to step
217.
Now, returning to step 494, if the undershoot delay timer has
expired, then the algorithm is directed to step 504 where the AUTO
and AUT02 flags are cleared, the sweep step counter value is
advanced and the undershoot values UNDR and UNDL are updated as
follows: UNDR=UNDR+(SPOUTN-TPSPOU) and UNDL=UNDL+(TPSPOU-SPOUTN),
where the SPOUTN values are the values stored by step 508 in a
second desired spout position register. These undershoot values,
UNDR and UNDL, are used in previously described steps 428 and 430
to calculate the spout position targets.
Thus, the undershoot values are not updated in step 504 until step
494 has determined that the undershoot delay timer (1 sec.) has
expired. After 504, the algorithm returns to 217.
Returning now to step 492, if the AUT02 flag has been cleared (as
in steps 502 or 504), then step 492 will direct the algorithm to
step 506 which determines whether the spout has gone past the
target position represented by the TARGET values of steps 428 and
430. If no, the algorithm returns to step 217. If yes, the
algorithm proceeds to step 508 which: (a) generates a "stop
movement" command, (b) stores the current desired spout position
value, SPOUTN, in a second register (separate from the first
register which contains the SPOUTN value from step 388) for use in
determining the undershoot values in step 504, (c) starts the
undershoot delay timer, (d) starts the sweep mode delay timer, (e)
sets the AUT02 flag, and (f) starts the relay delay timer. After
508, the algorithm returns to step 217.
Returning now to step 490, if the AUTO flag is not set (as when
cleared in step 504), then step 490 directs the algorithm to step
510 which again executes steps 700-708 of the check limit routine
of FIG. 7. If a "move right" or "move left" command is generated,
then step 512 direct the algorithm to step 514. Step 514: (a)
outputs the movement command to micro outputs P10 or P11, (b) sets
the AUTO flag, (c) clears the undershoot delay timer, (d) starts
the relay delay timer, and (e) clears the sweep mode flag. After
step 514, the algorithm returns to step 217. If in step 512, the
movement command was "stop", then step 512 directs the algorithm to
steps 516.sub.]526 (FIG. 4p). Steps 516-526 determine whether the
sweep delay timer is running, whether the hysteresis flag is set
(to prevent sweep mode operation when in a turn), whether the sweep
mode switch 104 is open, and whether the sweep mode flag is set (as
in 526). If the result of any of the determinations of steps
516-520 is yes, then the algorithm is directed to step 217 and no
spout movement is begun. However, if the results of 516-520 are all
no, then the algorithm proceeds to 522 which directs the algorithm
to 524 if the sweep mode flag is not set. Step 524 prevents the
sweep mode flag from being set in step 526 unless the spout is
positioned within the central 25% of its wagon crop-receiving range
of positions. This prevents the spout from sweeping when the
operator manually moves the spout to a position outside of this
central 25% in order to fill a wagon while compensating for a side
hill or for a cross wind. Once the condition of 524 is met, then
the sweep mode flag will be set in 526 and the next time through,
step 522 will direct the algorithm to step 528, which causes the
spout to be moved toward its next sweep mode target position, as
determined by steps 423, 428 and 430. Step 528 also restarts the
sweep mode delay timer and sets the auto movement flag. After steps
526 and 528, the algorithm returns to step 217.
Referring now to FIG. 7, the check limit and command generating
routine begins at step 700 which determines whether the sensed
spout position value, TSPOU, is greater than the spout position
range end point value, LIMHI. If yes, the routine proceeds to steps
704 and 710 which cause the generation and output of a "move right"
command signal which will activate relay 90 and move the spout 14
to the right. If not, then the routine proceeds to step 702 which
determines if the sensed spout-position value, TSPOU, is less than
the spout position range end point value, LIMLO. If yes, the
routine proceeds to steps 706 and 710 which cause the generation
and output of a "move left" command signal which will activate
relay 92 and move the spout 14 to the left. If not, then the
routine is directed to steps 708 and 710 which cause the generation
and output of "stop" command signals which turn both relays 90 and
92 off and thus stop movement of the spout 14.
In this manner, this routine generates command signals which will
cause the spout 14 to move toward the wagon crop-receiving range of
spout positions (represented by LIMHI and LIMLO) after the operator
has completed a manual movement of the spout 14 outside of this
range by use of a switch 51. Thus, when the forage harvester is
going through a thistle patch, the operator may manually move the
spout outside of the wagon crop-receiving range of positions by
using switch 51. Then, when switch 51 is de-activated, the spout 14
will be returned to the edge of the crop-receiving range in
response to the command signals generated by steps 448 or 466.
Referring now to FIG. 8, the manual test routine begins at 802
wherein the signals at micro relay sense inputs P04 and P05 are
compared to the signals at control outputs P10 and P11 to determine
if a signal is present at lines 66 or 68 without an actuation
signal being present at the corresponding control output. If so,
this is interpreted as a manual operation via switch module 50 and
step 804 directs the routine to step 806. If not, it means that a
manual operation has not been performed and step 804 directs the
routine to return to the main algorithm. Note that if relay 90 or
92 was recently de-activated (as indicated by the relay delay timer
still running), then the appropriate left or right signal which
might be present is not treated as a manual input.
In step 806, the following operations are performed: the P10 and
P11 control outputs are turned off to prevent automatic movement of
the spout 14; a manual operation flag is set; an automatic flag and
a sweep mode flag are cleared; the sweep delay timer is reset; the
turn delay timer is cleared; and the undershoot delay timer is
cleared. The routine then returns to the main algorithm so that the
manual control of the spout can continue without interference.
The conversion of the above-described flow chart into a standard
language for implementing the algorithm described by the flow chart
in a digital data processor, such as a microprocessor, will be
evident to those with ordinary skill in the art.
While the invention has been described in conjunction with a
specific embodiment, it is to be understood that many alternatives,
modifications, and variations will be apparent to those skilled in
the art in light of the aforegoing description. For example, the
control system described herein could be adapted to control the
discharge spout on any agricultural machine with an attached
collector vehicle or with a non-attached collector vehicle using a
non-mechanical collector vehicle position sensor. Accordingly, this
invention is intended to embrace all such alternatives,
modifications, and variations which fall within the spirit and
scope of the appended claims.
* * * * *